Club 80-90 Forums

This happened to me..
It was discovered that the split charge relay got stuck.
And permenantly connected the twp batteries.
A new relay sorted that out

kevtherev wrote:This happened to me..
It was discovered that the split charge relay got stuck.
And permenantly connected the twp batteries.
A new relay sorted that out

Thanks. I think the plan of action now is to strip the old setup out and fit new, going to take the opportunity to run better gauge cable and a better sensing relay.

Are you sure you want a VSR....... I'm happier with old school simple relay

Unless you've changed it, the cigarette lighter socket would normally run off the main starter battery.

tforturton wrote:Unless you've changed it, the cigarette lighter socket would normally run off the main starter battery.

Yep, all set to run off the leisure in this one, I believe the other half had it plugged into a 2-prong type power socket into a cig light adapter as well, which also draws from leisure.

In regards to a sensing relay, I've been having a good look over the setup in my friends van with a similar install, I must say it looks a lot better than the 'homebrew' looking setup I currently have, so I can only see it being an improvement

937carrera wrote:Are you sure you want a VSR....... I'm happier with old school simple relay

I like simplicity and in this case this is the best and most simplistic way.
Fancy dan electronics tend to fall over with heavy work

My old relay was 30 years old before it stuck

VW's motto of "Nothing is reliable as a volkswagen" (annoyingly and inappropriately used post-vdub) came out of its original approach to keeping everything simple on the classic beetle. Less to go wrong. I too favour a simple relay for split charging. Cheap to replace if they do ever go wrong and they give many years of service. Last one I bought was a nice 80amp Bosch relay on a boot sale for £1.

Fortunately the few of us making mods also stick to simpler and easy/cheap to replace components too. Keep it simple.

Well, everything is now in, however, this highlighted another issue...despite my alternator putting out around 14v charge, I'm down to 13v by the time I'm at the starter battery...not enough to activate the 13.3v for the VSR. I've rigged up something with a more traditional relay for now to get me charging for a trip this coming weekend, however, this does send me down the rabbit hole of examining/cleaning/replacing cables when I return, I imagine I have some rather old and crusty wiring and connectors sapping the power. Off to the search function I go

On a side note. I currently have an early (with connector), 45amp alternator. Is there any merit to upgrading to the 65amp that Brickwerks stock in this fitment? I'm not against spending the money for the good of the van if it will benefit it. At the same time, if it doesn't need it, I'll keep hold of my beer tokens

Try changing regulator for a 14.5v rather than the 14v one as an interim measure. Otherwise: https://club8090.co.uk/wiki/VW ... ain_cables" onclick="window.open(this.href);return false;

Standard relay good, VSR bad

As well as the + side, have a look at the battery / engine earths, if they are crusty it can have the same effect.

On the alternator, the bigger one will recharge your battery quicker, at the expense of a very small amount of drag on engine power, something only a modern manufacturer would worry about for statutory fuel efficiency tests. Check if it has the 14.5v regulator in already.

As always, thank you for your help gents. I'll ask the question about the voltage reg, I notice Brickwerks sell the 14.5v items as well, so may as well upgrade the new alternator with one if I'm going this far. Must say, as a 'DF' owner, 'drag on engine power' scares me a tiny bit, I've not got much to start with! hah

I wasn't going to mention the DF engine, but don't worry, it's not a lot, here's some maths

45A * 14v = 630W
65A * 14v = 910W

0.28 kW or 0.37 HP maximum, ignoring conversion efficiency, you're not going to notice it.

See if BW will sell you the alternator (by email) with the 14.5v regulator already fitted, they will be able to sell the 14v one to someone else, keep hold of a few beer tokens

It could just simply be a faulty regulator anyway. Certainly the cheapest fix and best to try that first.

Dubworth wrote:Well, everything is now in, however, this highlighted another issue...despite my alternator putting out around 14v charge, I'm down to 13v by the time I'm at the starter battery...not enough to activate the 13.3v for the VSR.

Just put the VSR near to the alternator where there is v. little voltage drop! Why have it at the other end - laziness?